Sonic Speakers Facility Design Chris Chesla Dan Hovde Tony Niemczyk Mike Rosenthal

Outline  Introduction  Approach and Methodology  Results  Recommendations  Conclusion

Introduction  Sonic Speakers purchased new Facility  Engineering team New layout New design of production Plan growth for next five years

Approach and Methodology  Current Situation  Lean Manufacturing  Line Balancing  Inventory Control  Layout  Truck Routing

Current Situation  120,000 square feet  16 docks  Work 10 hr days 5 days a week

Lean Manufacturing  Used in plant layout Minimize distances traveled Balance lines  Assembly lines Based on pull system Cross-trained workers  Inventory Reduce 20%

Line Balancing  Cellular Design Cross-trained teams In charge of Quality  Lines Based on speaker size Designed to peak demands Run north to south  Puts finished products close to dock

Inventory Control  ABC inventory Control Most often used  Easiest to access Least used  Hardest to access Rank  A ~ Highest Volume Flow  B ~ Medium Volume Flow  C ~ Lowest Volume Flow

Plant Layout  Warehouse 27,500 square feet including aisle 12 foot aisles Stack three pallets high  Wood and Carpet stored separate Located near production  Assembly located in center Easy access to all areas

Truck Routing  15 routes  6 to 7 orders per truck  Shipped 3 times a week  Filled in reverse order

Results  Tact times Yellow ~ 24 min Blue ~ min Green ~ min Red ~ min  Line efficiencies

Results Cont.  Reduction of Inventory work days/ year250 YearT/YPercent CubePallets in CubePallet Reduction % % % % %343

Recommendations  Short-term Purchase necessary items Classify inventory Arrange inventory Develop truck routes Manage Flow  Long term Diminish Inventory Improve line efficiency Multifunctional work staff

Conclusion  Cellular manufacturing  Engineered plant layout  Lean Manufacturing Decline inventory Reduce travel  Inside the plant  Outside the plant